Bag-in-box beverage container

ABSTRACT

A container assembly for use in containing fluids includes an outer shell having a plurality of sidewalls, a top portion, a handle formed in the top portion, and an aperture formed in one of the sidewalls. The outer shell is formed from a blank. A securement strip is formed on the top portion. A securement slit is formed on the top portion and configured to receive the securement strip.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application claims the benefit of U.S. Provisional Patent Application No. 62/206,925, filed on Aug. 19, 2015. The entire disclosure of the above patent application is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to a beverage container and more particularly to a portable bag-in-box container.

BACKGROUND OF THE INVENTION

This section provides background information related to the present disclosure that is not necessarily prior art.

Many commercial food retailers, restaurants, catering services, and the like provide catering, delivery, or to-go services for consumers for multi-person gatherings such as meetings, parties, or other events. Food retailers such as caterers and coffee shops often provide hot and cold beverages such as coffee and tea, for example, in a disposable container for containing large volumes of product. In order to provide for multi-person gatherings, portable and reusable containers exist in order to transport the beverage from the food retailer's facility to the designated location of the gathering. However, reusable containers can be disadvantageous due to costs of operation in retrieving and reusing the containers. The reusable containers can also can take up storage space, become damaged due to wear and tear, and/or become the subject of theft.

To overcome some of these disadvantages, disposable bag-in-box containers are used. For example, U.S. Pat. No 7,007,825 discloses a bag-in-box beverage container and dispenser. The beverage container incorporates an outer shell of corrugated paperboard material and an inner liquid containing bag. The outer shell can be formed from a blank and includes a handle for carrying the beverage container.

However, problems exist with current disposable beverage containers. Current containers can require a complex assembly and/or unnecessary materials and the complexity results in higher manufacturing costs. When assembled, the beverage containers may not be stackable due to protruding features (such as protruding handles and the like) which takes up storage space when transporting multiple beverage containers. The complexity can also lend to damage of and a loss of integrity of the container. Additionally, disposable beverage containers may include handles that are unwieldy and insufficiently durable for comfortably handling large volumes of beverages such as three gallons, for example. As such, it has become increasingly important to improve the structural integrity of the handle. Furthermore, some of the current containers are unable to substantially maintain the desired range of temperatures over a long period of time. Cool beverages may warm up too quickly and hot beverages may cool down too quickly.

It would therefore be desirable to provide a portable disposable container for beverages that is durable, ergonomically configured, and substantially maintains a desired temperature of beverages that can also be easily manufactured and assembled while providing for a reduction in manufacturing costs.

SUMMARY OF THE INVENTION

The present technology includes articles of manufacture, methods, systems, and kits that relate to a beverage container and method of assembling the beverage container that is durable, ergonomically configured, and substantially maintains a desired temperature of beverages that can also be easily manufactured and assembled while providing for a reduction in manufacturing costs.

According to embodiment of the disclosure, a container assembly for use in containing fluids is disclosed. The container assembly includes an outer shell having a plurality of sidewalls, a top portion, a handle formed in the top portion, and an aperture formed in one of the sidewalls. The outer shell is formed from a blank. A securement strip is formed on the top portion. A securement slit is formed on the top portion and configured to receive the securement strip.

According to another embodiment of the disclosure, a blank for forming an outer shell for a container assembly for use in containing fluids is disclosed. The blank includes a plurality of panels hingedly coupled to each other. An aperture is formed in one of the plurality of panels. The blank includes a pair of top retaining flaps. A first one of the pair of top retaining flaps is hingedly coupled to a first one of the plurality of panels. A second one of the pair of top retaining flaps is hingedly coupled to a second one of the plurality of panels. The blank further includes a pair of top forming flaps. A first one of the top forming flap is hindgedly coupled to a third one of the plurality of panels. A second one of the pair of top forming flaps is hingedly coupled to a fourth one of the plurality of panels. Each of the pair of top forming flaps includes a first section, a second section, and a third section hingedly coupled to each other along a fold line. The pair of top forming flaps configured to cooperate with the pair of top retaining flaps to form a top portion of the outer shell.

In yet another embodiment of the disclosure, a kit for forming an outer shell for a container assembly for use in containing fluids is disclosed. The kit includes a blank for forming an outer shell. The blank includes a first flap having a securement strip extending therefrom and a second flap having a securement slit formed thereon. The securement slit is configured to receive the securement strip. The kit also includes an angle insert.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawing which:

FIG. 1 is a front perspective view of a container assembly according to embodiment of the invention;

FIG. 2 is a front perspective view of the container assembly of FIG. 1, wherein a top portion of the container assembly is in an open position;

FIG. 3 is a top perspective view of the container assembly of FIG. 1;

FIG. 4 is a partially disassembled front perspective view of the container assembly of FIG. 1, including an outer shell and an angle insert;

FIG. 5 is a top plan view of a blank for forming the outer shell of the beverage container FIG. 1; and

FIG. 6 is a bottom plan view of the blank for forming the outer shell of the beverage container of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. The terms top and bottom are used herein merely for descriptive convenience. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical. The term “hingedly” used herein means foldable and rotatable about a fold line or configured to bend or fold with respect to another portion.

FIGS. 1-4 illustrate an embodiment of a portable container assembly 10 for use in containing and transporting a liquid such as a beverage (coffee, tea, iced coffee, iced tea, hot chocolate, lemonade, etc.). However, the container assembly 10 can be used to contain other food liquid products and semi-liquid products such as a soup, for example, as desired. The container assembly 10 includes an outer shell 30 and an angle insert 20. The container assembly 10 is configured to receive and support an inner liner or bag (not shown), as is known in the art, the bag having a spout 22. A dispensing assembly 24 such as a nozzle, for example, is coupled to the spout 22 of the inner liner 20. The dispensing assembly 24 can include seals, fastening means, or other devices as desired to facilitate coupling to the spout 22 and dispensing the beverage from the inner liner, and thus from the container assembly 10. In certain embodiments, the inner liner is a flexible and durable material configured for use with food products and maintaining a desired temperature thereof such as various plastics including ethylene vinyl alcohol (EVOH), for example. However, other materials can be used as desired.

The outer shell 30 of the container assembly 10 includes a plurality of sidewalls 32, 34, 36, 38, a top portion 40 recessed inwardly from an end of the sidewalls 32, 34, 36, 38, and a bottom portion 42. The top portion 40 includes a handle 44 configured to permit a user to securely and ergonomically transport the container assembly 10. The bottom portion 42 has an bottom-set up (not shown), constructed by means of hinged bottom flaps (further described hereinbelow), that securely closes the bottom portion 42 of the outer shell 30. An aperture 48 having cut flaps ## (shown in the blank in FIGS. 5 and 6) is formed in the side wall 36 for receiving the spout of the inner liner. In the non-limiting example illustrated, the outer shell 30 has one aperture 48, however it is understood the outer shell 30 can have any number of apertures, as desired.

In certain embodiments, the container assembly 10 includes the angle insert 20 received by the outer shell 30. The angle insert 20 is adapted to cause fluid within the inner liner to flow towards the spout 22. The angle insert 20 has a first end 26 and a second end 28. The angle insert 20 tapers from the second end 28 to the first end 26 with respect to a supporting surface of the container assembly 10 or a bottom edge of the container assembly 10. The first end 26 of the angle insert 20 is positioned adjacent the side wall 36 with the aperture 48 and the second end 28 of the angle insert 20 is positioned adjacent the opposing sidewall 32 when the angle insert 20 is received in the outer shell 30. The first end 26 of the angle insert 20 is positioned below the aperture 48 to permit the spout 22 to be inserted through the aperture 48 and cause the fluid in the inner liner to flow towards the aperture 48 through the spout 22. In further embodiments, a pair of reinforcing collars 52, each having an aperture formed therein, is disposed adjacent opposing surfaces 29, 31 of the outer shell 30. The pair of collars 52 receives the spout 22 in the apertures to maintain and support the spout 22 and/or dispensing assembly 24 within the aperture 48 of the outer shell 30.

As shown in the embodiments illustrated in FIGS. 5-6, the outer shell 30 is formed from a one-piece blank 60 made from a corrugated material, flute styled corrugated fiberboard, or other style of corrugated fiberboard. However, similar paper-based materials, having similar performance characteristics, may be employed if desired, as well as corrugated plastics or non-corrugated plastics, or other foldable material. The blank 60 includes a first panel 62, a second panel 64, a third panel 66, and a fourth panel 68 to form the respective sidewalls 32, 34, 36, 38 of the outer shell 30. The panels 62, 64, 66, 68 are each hingedly coupled to at least one adjacent panel along fold lines 61. The fold lines 61 can be formed by perforations, scored marks, depressions, or other means to hingedly couple the panels 62, 64, 66, 68 to each other.

The blank 60 further includes top retaining flaps 70, first bottom forming flaps 72, top forming flaps 78, and second bottom forming flaps 80. A first one of the first bottom forming flaps 72 is hingedly coupled to a first end of the first panel 62 and a second one of the first bottom forming flaps 72 is hingedly connected to a first end of the third panel 66. Each of the first bottom forming flaps 72 is hingedly coupled to the respective panels 62, 66 by a fold line 73. A first one of the second bottom forming flaps 80 is hingedly coupled to a first end of the second panel 64 and a second end of the second bottom forming flaps 80 is hingedly coupled to a first end of the fourth panel 68. Each of the second bottom forming flaps 80 is hingedly coupled to the respective panels 64, 68 by a fold line 81. The fold lines 73, 81 can be formed by perforations, scored marks, depressions, or other means to hingedly couple the bottom forming flaps 72, 80 to the respective panels 62, 64, 66, 68.

A first one of the top retaining flaps 70 is hingedly coupled to a second end of the first panel 62 and a second one of the top retaining flaps 70 is hingedly coupled to a second end of the third panel 66. Each of the top retaining flaps 70 is hingedly coupled to the respective panels 62, 66 by a fold line 71. The fold line 71 can be formed by perforations, scored marks, depressions, or any other means to hingedly couple the top retaining flaps 70 to the respective panels 62, 66. Each of the top retaining flaps 70 includes a recess 74 formed therein, tabs 76 extending therefrom, and securement strips 77 extending from opposing sides thereof. The recess 74 is formed in an edge of the top retaining flaps 70 opposite the fold line 71. In certain embodiments, each of the top retaining flaps 70 includes the two tabs 76 with the recess 74 formed therebetween and two securement strips 77 extending from opposing sides of the top retaining flaps 70. However, the top retaining flaps 70 can include any number of tabs such as one tab, three tabs, four tabs, or more and one securement strip, three securement strips, four securement strips, or more.

A first one of the top forming flaps 78 is hingedly coupled to a second end of the second panel 64 and a second one of the top forming flaps 78 is hingedly coupled to a second end of the fourth panel 68. Each of the top forming flaps 78 is hingedly coupled to the respective panels 64, 68 by a fold line 79. Each of the top forming flaps 78 coupled to the respective panels 64, 68 include a first section 82, a second section 84, and a third section 86 laterally extending the width of the second panel 64 and the fourth panel 68. The sections 82, 84, 86 are hingedly coupled to each other along fold lines 81. The fold lines 81 can be formed by perforations, scored marks, depressions, or any other means hingedly coupling the sections 82, 84, 86 to each other. In certain embodiments, the fold lines 81 are formed by reversed male-to-female scoring with the male scoring formed on a first surface 63 of the blank 60 and a female scoring on a second surface 65 of the blank 60.

Slots 88 are formed in each of the second sections 84 of the top forming flaps 78 and configured to receive and engage with the tabs 76 of the top retaining flaps 70 coupled to the first panel 62 and the third panel 66. As illustrated in the embodiment shown, there are two slots 88 formed in each of the second sections 84. However, there can be any number of slots as desired such as one slot, three slots, four slots, or more, as desired.

Securement slits 89 are formed in each of the first sections 82 of each of the top forming flaps 78 and configured to receive and engage the securement strips 77 of the top retaining flaps 70. As illustrated in the exemplary embodiment shown, there are two securement slits 89 formed in each of the first sections 82 of the top forming flaps 78. Each of the securement slits 89 is angled at an acute angle such as about 45 degrees, with respect to the fold lines 81. Each of the securement slits 89 extends from the fold line 81 towards an intermediate portion of the first section 82 of the top forming flaps 78. It is understood alternate angles and configurations can be contemplated, as desired.

Each of the third sections 86 of the top forming flaps 78 include a handle aperture 90 formed therein and hook tabs 94 extending outwardly from each of the third sections 86 of the top forming flaps 78. The hook tabs 94 are configured to be received in the recesses 74 formed in the top retaining flaps 70.

Each of the second bottom forming flaps 80 coupled to the second panel 64 and the fourth panel 68 include tabs 92 hingedly coupled thereto. The tabs 92 are hingedly coupled to the second bottom forming flaps 80 along fold lines 91. The fold lines 91 can be formed by perforations, scored marks, or any other means hingedly coupling the tabs 92 to the second bottom forming flaps 80.

In certain embodiments, the reinforcement collars 52 are releasably coupled to the blank 60 along perforated lines. In the embodiment illustrated, the reinforcement collars 52 are releasably coupled to the top forming flap 78 coupled to the second panel 64 and one of the top retaining flaps 70. However, the reinforcement collars 52 can be releasably coupled to any portion of the blank 60 as desired.

During assembly, the panels 62, 64, 66, 68 form a tube by gluing a glue tab 96 to the first panel 62 to form the plurality of sidewalls 32, 34, 36, 38. The top retaining flaps 70 and the top forming flaps 78 cooperate with each other to form both the top 40 of the outer shell 30 and the handle feature 44 of the outer shell 30. To form the top 40 and the handle feature 44 of the outer shell 30, the top forming flaps 78 are folded inwardly with respect to the outer shell 30 along the fold lines 81. The top forming flaps 78 are folded towards each other, wherein the first sections 82 are substantially parallel with the second panel 64 and the fourth panel 68 in tube form, the second sections 84 are substantially perpendicular to the second panel 64 and the fourth panel 68 in tube form, and the third section extends outwardly from the first surface 63 of the blank 60 and substantially parallel with the second panel 64 and the fourth panel 68.

The top retaining flaps 70 are folded inwardly with respect to the outer shell 30 at an acute angle, such as 45 degrees, with respect to the first panel 62 and the third panel 66 in tube form. Once folded, the tabs 76 are received through the slots 88 of the top forming flaps 78. A portion of the tabs 76 extends a distance from the second surface 65 of the blank 60 to maintain the top retaining flaps 70 at the desired acute angle. The hook tabs 94 are received through the recesses 74. The securement strips 77 are received by and engage with the securement slits 89. The tabs 76, the securement strips 89, and the hook tabs 94 are configured to cooperate with the respective slots 88, the securement slits 89, and the recesses 74 to stabilize, strengthen, and maintain the handle in the desired recessed position.

The bottom forming flaps 72, 80 cooperate with each other to form the bottom of the outer shell 30. In certain embodiments, the aperture 48 of the outer shell 30 for receiving the spout 22 is formed in the third panel 66. However, the aperture 48 can be formed in any panel as desired. Additionally, more than one aperture can be formed in the blank 60 as desired.

While not illustrated, the container assembly 10 can include a caddy or storage container for storing beverage condiments, server wear, utensils, napkins, etc. The blank can include further hooked tabs or other attachment means in which, upon assembly of the outer shell, a caddy can be attached to the outer shell. Additionally, the container assembly 10 can include indicia disposed on the surfaces of the container assembly. Examples of indicia include numbers, letters, pictures, advertisement art, warning labels, packaging information, measurement conversions, etc. The indicia can be applied to the surface of the blank 60 before, during, and/or after a blank forming process. The indicia can also be applied to a surface of the assembled outer shell 30, as desired.

A method of forming the container assembly 10 includes the steps of using the blank 60 to assemble the outer shell 30, assembling the angle insert 20 and inserting the angle insert 20 into the outer shell 30 such that a slope of the angle insert 20 tapers towards the aperture 48 of the outer shell 30, and inserting the inner liner. The method further includes the steps of filling the inner liner with the beverage, coupling the dispensing assembly 50 to the spout 22 of the inner liner 20, and preparing for use. IT is understood, the angle insert 20 can be formed from a separate blank or as a portion of the blank 60, if desired.

In certain embodiments, a kit can be provided, manufactured, or sold that includes at least one blank 60 for forming the outer shell 30, at least one angle insert 20, and at least one inner liner to form the container assembly 10. The kit can also include the container assembly fully assembled or partially assembled. The kit can further include the nozzle assembly 50, funnels, tubes, syphoning apparatuses or tools, instruction sets, caddies, or any other accessories desired for transporting and providing portable beverages.

In application, the container assembly 10 can be configured to contain a beverage in bulk such as 3 gallons of the beverage, for example. However, the container assembly can be configured to include any amount of the beverage as desired, such as more than 3 gallons or less than 3 gallons. The angle insert 20 disposed in the outer shell 30 is positioned therein to support the liner to cause the beverage in the liner to be gravity fed to the spout 20 which in turn is dispensed when in the container assembly 10 is in use. Advantageously, the angle insert 20 minimizes a volume of an internal space created by the outer shell 30 for receiving the liner, which minimizes a transfer of heat from the liquid in the liner.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions. 

What is claimed is:
 1. A container assembly for containing fluids comprising: an outer shell having a plurality of sidewalls and a top portion, an aperture formed in one of the sidewalls, the outer shell formed from a blank; a handle formed in the top portion; a securement strip formed on the top portion; and a securement slit formed on the top portion configured to receive the securement strip.
 2. The container assembly of claim 1, further comprising an angle insert received in the outer shell.
 3. The container assembly of claim 2, where the angle insert tapers towards the aperture.
 4. The container assembly of claim 1, wherein the handle is recessed with respect to a top edge of the outer shell.
 5. The container assembly of claim 1, further comprising a bottom portion formed by hinged bottom flaps.
 6. The container assembly of claim 1, further comprising a reinforcement collar disposed adjacent the aperture.
 7. A blank for forming an outer shell for a container assembly for use in containing fluids, the blank comprising: a plurality of panels hingedly coupled to each other, one of the plurality of panels having an aperture formed therein; a pair of top retaining flaps, a first one of the pair of top retaining flaps hingedly coupled to a first one of the plurality of panels, a second one of the pair of top retaining flaps hingedly coupled to a second one of the plurality of panels; and a pair of top forming flaps, a first one of the top forming flap hindgedly coupled to a third one of the plurality of panels, a second one of the pair of top forming flaps hingedly coupled to a fourth one of the plurality of panels, each of the pair of top forming flaps including a first section, a second section, and a third section hingedly coupled to each other along a fold line, the pair of top forming flaps configured to cooperate with the pair of top retaining flaps to form a top portion of the outer shell.
 8. The blank of claim 7, wherein each of the pair of top retaining flaps has a recess formed therein.
 9. The blank of claim 8, wherein each of the pair of top forming flaps has a hook tab extending therefrom, the hook tab of each of the pair of top forming flaps configured to be received in the recess of an opposing one of the pair of top retaining flaps.
 10. The blank of claim 7, wherein each of the pair of top retaining flaps has a pair of securement strips extending therefrom.
 11. The blank of claim 10, wherein each of the pair of top forming flaps has a pair of securement slits formed therein, the pair of securement slits configured to receive the pair of securement strips.
 12. The blank of claim 11, wherein each of the securement slits is angled at an angle with respect to the fold line.
 13. The blank of claim 10, wherein each of the pair of securement strips extends from a side of each of the pair of top retaining flaps.
 14. The blank of claim 7, wherein the third section of each of the pair of top forming flaps includes a handle aperture formed therein.
 15. The blank of claim 7, wherein a reinforcement collar is coupled to one of the pair of top forming flaps, the reinforcement collar configured to be removed from the one of the pair of top forming flaps and be aligned with the aperture formed in the one of the plurality of panels during assembly of the container assembly.
 16. The blank of claim 7, wherein a glue tab extends from one of the plurality of panels.
 17. The blank of claim 7, further comprising a plurality of bottom forming flaps, each of the plurality of bottom forming flaps extending from and hingedly coupled to one of the plurality of panels.
 18. A kit for forming an outer shell for a container assembly for use in containing fluids, the kit comprising: a blank for forming an outer shell, the blank including a first flap having a securement strip extending therefrom and a second flap having a securement slit formed thereon, the securement slit configured to receive the securement strip; and an angle insert.
 19. The kit of claim 18, wherein the angle insert has a first end and a second end, the angle insert tapering from the second end to the first end with respect to a bottom edge of the container assembly after assembly thereof.
 20. The kit of claim 18, further comprising a dispensing assembly. 